Disc Wheel with Internal Bracing

ABSTRACT

A bicycle disc wheel comprises a first disc panel and a second disc panel. The first disc panel has a first side outer surface and a first side inner surface and the second disc panel has a second side outer surface and a second side inner surface. The first side outer surface radially extends from a first disc panel outer perimeter to a center opening and the second side outer surface radially extends from a second disc panel outer perimeter to the center opening. The second side inner surface faces the first side inner surface. A brace is coupled to the first side inner surface and the second side inner surface that provide radial and axial structural support to the disc panels.

RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationNo. 62/507,038, entitled “Ribbed Track Disk,” filed May 16, 2017, whichis hereby fully incorporated by reference herein in its entirety.

TECHNICAL FIELD

This disclosure relates generally to a bicycle disc wheel with internalbraces and a method of manufacturing a bicycle disc wheel with internalbraces.

BACKGROUND

Rim-and-spoke type wheels are the most commonly used wheels onrecreational and racing bicycles. A rim-and-spoke wheel has an outer rimto which the bicycle tire mounts and a set of spaced spokes that extendfrom the outer rim to a center hub shell. Typically, air can easily flowthrough exposed open spaces between the spokes when the wheel is ridden.The flow of air over and around the spokes in these spaces is asignificant source of drag.

Unlike a conventional rim-and-spoke wheel, a disc wheel has sidesurfaces that are disc-shaped and have no significant open spaces. Discwheels do not experience the same drag as rim-and-spoke wheels, but theyare often less maneuverable and more difficult to control in crosswinds.Disc wheels are thus primarily used for in-door track events and shortersprint events.

One common method of forming a disc wheel is to attach side panels to aconventional rim-and-spoke wheel to attach panels that can act as afairing to cover the open spaces between the spokes. The spokes stillprovide the primary structural support to the rim and, for the drivewheel, transfer the rider's power from the hub to the rim. Therim-and-spoke wheel is rideable without the fairing. Conversely, thefairing does not form a rideable wheel in the absence of therim-and-spoke wheel.

Other methods of making disc wheels have also been developed that do notrely on an existing rim-and-spoke wheel. One such method involves curingcarbon fiber composite material over a honeycomb type core materialformed of another composite. The honeycomb core aids in manufacture ofthe wheel and provides structural support to the carbon fiber. However,manufacturing wheels according to this method is difficult. To create abond of adequate strength between the carbon fiber and honeycomb core, asufficient amount of thermoset material must flow into the honeycombcore during molding. Achieving an adequate bond is difficult when usingpre-impregnated carbon fiber because the resin in the carbon fiber isalready partially cured and cannot easily flow into the honeycomb core.On the other hand, it is difficult to do a “hand layup” of carbonfiber—that is a layup without using a pre-preg carbon fiber—in complexshapes. Consequently, disc wheels formed over a honeycomb core oftenhave flat sides, which may not provide optimum aerodynamics for thewheel.

According to another method, disc wheel panels can be formed by moldingcarbon fiber composite material around a structural foam core to formpanels that have a sandwich construction. The panels can then be joinedtogether to form a disc wheel. The structural foam layer in the panelsprovides additional structural support to the carbon composite. Thestrength of carbon composite materials typically increases, up to acertain point, as the pressure, temperature and time used in the curingprocess increases. However, common structural foams used in somesandwich construction processes have a fairly low pressure tolerance.Thus, such processes typically occur at low pressures (e.g., less than20 psi). Forming a disc wheel in this fashion unduly limits the strengthof the wheel or requires longer molding times.

SUMMARY

According to one embodiment, a bicycle disc wheel comprises a first discpanel, a second disc panel and an internal brace that provides radialand axial structural support to the first disc panel and second discpanel. The first disc panel has a first side outer surface and a firstside inner surface. The first side outer surface radially extends from afirst disc panel outer perimeter to the center opening. The second discpanel has a second side outer surface and a second side inner surface.The second side outer surface radially extends from a second disc panelouter perimeter to the center opening. The second side inner surface isaxially spaced from and facing the first side inner surface. Theinternal brace is coupled to the first side inner surface and the secondside inner surface. According to one embodiment, the brace may comprisea rib. The brace may be molded in the first panel or the second panel.

The bicycle wheel may comprise a plurality of braces. The braces, insome embodiments, may comprise molded-in braces that molded in the firstdisc panel or the second disc panel.

A brace may comprise a radially extending rib. The radially extendingrib can be coupled to the first side inner surface and the second sideinner surface. The radially extending rib may extend from a hub centerportion to a circumferential perimeter wall of the disc wheel. Inanother embodiment, the radially extending rib may be spaced from thehub center portion or the perimeter wall. The radially extending rib maybe molded in the first disc panel or second disc panel.

In another embodiment, a brace may comprise a circular rib. The circularrib can be coupled to the first side inner surface and the second sideinner surface. The circular rib may be concentric about a center opening(e.g., a hub opening) of the disc wheel. The circular rib may be moldedin the first disc panel or the second disc panel.

The second disc panel can be bonded to the first disc panel at a bondingsurface. According to one embodiment, the bonding surface may be acircumferential bonding surface on the inner side of the first panel, abonding surface on a brace, a bonding surface of a hub flange or otherbonding surface.

The disc wheel can be an all composite material (e.g., carbon fibercomposite) disc wheel. The disc wheel may or may not have a core.

Another embodiment comprises a method of manufacturing a bicycle discwheel. The method includes positioning a panel material, such as acarbon fiber composite material or other composite material, on amolding surface of a mold. The method further includes arranging a setof shaped pieces and braces on an inner surface of the panel material.According to one embodiment, the braces comprise ribs. The shaped piecescan be configured to support the braces in the mold and may be formed ofa flexible, expanding material. The method further includes baking themold to cure the panel material and braces into a first disc panel withmolded-in braces. The method can further include removing the set ofshaped pieces from between the molded-in braces. A second disc panel canbe coupled to the first disc panel to form a disc wheel with themolded-in braces.

Arranging the set of shaped pieces and braces on the inner surface ofthe panel material can include arranging the set of shaped pieces andbraces to form a radially extending rib. In one embodiment, the radiallyextending rib extends radially from an internal hub center to acircumferential perimeter wall. In another embodiment, the radiallyextending rib is spaced from the hub center or circumferential perimeterwall. In addition or in the alternative, arranging the set of shapedpieces and braces on the inner surface of the panel material caninclude, in one embodiment, arranging the set of shaped pieces andbraces to form a circular rib that is concentric with a central openingof the wheel.

The second disc panel can bonded to the first disc panel at a bondingsurface. In one embodiment, bonding the second disc panel to the firstdisc panel can include bonding an inner surface of the second disc panelto bonding surfaces of the molded-in braces. Bonding the second discpanel to the first disc panel may also include bonding the inner surfaceof the second disc panel to a circumferential bonding surface on aninner side of the first disc panel. Bonding the second disc panel to thefirst disc panel may include bonding the inner surface of the seconddisc panel to a hub flange of the first disc panel. Bonding the seconddisc panel to the first disc panel may include bonding a hub index to ahub center.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings accompanying and forming part of this specification areincluded to depict certain aspects of the invention. A clearerimpression of the invention, and of the components and operation ofsystems provided with the invention, will become more readily apparentby referring to the exemplary, and therefore non-limiting, embodimentsillustrated in the drawings, wherein identical reference numeralsdesignate the same components. Note that the features illustrated in thedrawings are not necessarily drawn to scale.

FIG. 1 is a perspective view of one embodiment of a disc wheel for abicycle.

FIG. 2 is front view of one embodiment of a disc wheel for a bicycle.

FIG. 3 is a cutaway view of one embodiment of a ribbed disc wheel.

FIG. 4 is a perspective view of one embodiment of a ribbed disc panel.

FIG. 5 is a perspective view of another embodiment of a ribbed discpanel.

FIG. 6 is a perspective view of another embodiment of a ribbed discpanel.

FIG. 7 is a perspective view of another embodiment of a ribbed discpanel.

FIG. 8 is a perspective view of another embodiment of a ribbed discpanel.

FIG. 9 is a sectional view of one embodiment of a mold for molding adisc panel.

FIG. 10 is a sectional view of one embodiment of a mold for molding adisc panel.

FIG. 11 is a perspective view of one embodiment of a mold portion.

FIG. 12 is a perspective view of one embodiment of a mold portion withpanel material positioned therein.

FIG. 13 is perspective view of one embodiment of shaped pieces ofmaterial used to support ribs during molding.

FIG. 14 is a sectional view of one embodiment of a rib wrapped on ashaped rib support.

FIG. 15 is a sectional view of one embodiment of panel material, ribsand rib supports positioned in a mold area.

FIG. 16 is a perspective view of one embodiment of panel material, ribsand shaped rib supports positioned in a mold area.

FIG. 17 is perspective view of another embodiment of shaped pieces ofmaterial used to support ribs during molding.

FIG. 18 is perspective view of yet another embodiment of shaped piecesof material used to support ribs during molding

FIG. 19 depicts several embodiments of ribs.

DETAILED DESCRIPTION

The disclosure and various features and advantageous details thereof areexplained more fully with reference to the exemplary, and thereforenon-limiting, embodiments illustrated in the accompanying drawings anddetailed in the following description. It should be understood, however,that the detailed description and the specific examples, whileindicating the preferred embodiments, are given by way of illustrationonly and not by way of limitation. Various substitutions, modifications,additions and/or rearrangements within the spirit and/or scope of theunderlying inventive concept will become apparent to those skilled inthe art from this disclosure.

Embodiments described herein provide an internally braced bicycle discwheel. Embodiments further provide a manufacturing method to make a verystiff and light bicycle disc wheel that includes internal braces (e.g.,carbon fiber ribs). The internal cross bracing allows the disc panels tobe lighter while keeping the stiffness and strength. According to oneembodiment, a disc wheel according to the teachings herein can be an allcomposite material disc wheel. In this context, an “all compositematerial” disc wheel refers to a wheel having a wheel disc that is madeentirely of a composite material from the center opening of the wheeldisc to a radially outer edge of the wheel disc. For example, an “allcarbon fiber” disc wheel refers to a wheel having a wheel disc that ismade entirely of a carbon fiber composite from the center opening of thewheel disc to a radially outer edge of the wheel disc. Furthermore,embodiments described herein can be spokeless. A rider's power can betransferred from the hub to the outer perimeter of the wheel by the discside panels rather than by spokes.

FIG. 1 and FIG. 2 are diagrammatic representations of one embodiment ofa disc type bicycle wheel 10 which is generally circular or disc shaped,and includes a hub portion 12, a tire engaging portion 14 at the wheel'sradial perimeter and first and second axially spaced, opposite sideouter surfaces 16, 18 that radially extend from the tire engagingportion 14 to the hub portion 12. A portion of first and second sideouter surfaces 16, 18 may comprise a brake engaging portion. The brakeengaging portion may have a radial extent that is slightly larger thanthe height of a typical bicycle brake caliper.

Hub portion 12 defines a hub opening in which a hub can be installed atthe wheel's radial center. The hub may include an axle portion that isrotatable independently of the remainder of the hub, and a flangeportion that extends radially outward for a short distance to engage aportion of the hub portion 12 of the wheel 10. The flange portion of thehub may be coupled to wheel 10 with fasteners or other mechanisms.

The tire engaging portion 14 is configured to receive a tire that can bemounted thereto. According to one embodiment, tire engaging portion 14is shaped to mount a clincher tire. According to another embodiment,tire engaging portion 14 is shaped to mount a non-clincher tire, such asa tubular tire that does not have tire beads. In the embodimentillustrated, tire engaging portion comprises a first circumferential lip20, a second circumferential lip 22 and a generally concavely disposedtire facing tire bed 24 that extends in a generally axial directionbetween the first and second circumferential lips 20, 22, and around thewheel 10.

The first side outer surface 16 forms the majority of the first outerside of the wheel 10 extending between the hub portion 12 and the tireengaging portion 14. The second side outer surface 18 forms the majorityof the second outer side of the wheel 10, which is axially opposed tothe first outer side of the wheel 10, extending between the hub portion12 and the tire engaging portion 14. First and second side surfaces 16,18 may have a planer, convex, concave or other shape. First and secondside surfaces 16, 18 can include surface features such as dimples orother features.

According to one embodiment, wheel 10 is generally symmetrical about aradially extending plane, so that the first and second side surfaces 16,18 are generally mirror-images of each other. In other embodiments,first and second side surfaces 16, 18 may have different shapes suchthat wheel 10 is asymmetrical about a radially extending plane.

Wheel 10 can be formed from disc panels that are molded or assembledtogether to form a disc wheel with internal braces. The disc panels mayhave a variety of configurations, some non-limiting examples of whichare discussed below in conjunction with FIGS. 3-8.

FIG. 3 illustrates a partially exploded cut away view of one embodimentof disc wheel 10. In the illustrated embodiment, disc wheel 10 comprisesa first disc panel 32 and a second disc panel 34 that can be coupledtogether to form a disc wheel. First disc panel 32 includes a first sidepanel 33 having first side outer surface 16 (FIG. 1 and FIG. 2) andfirst side inner surface 36. Second disc panel 34 includes a second discside panel 35 having second side outer surface 18 and second side innersurface 38 that faces first side inner surface 36. The first side outersurface 16 extends from a radial perimeter of first disc panel 32 to hubopening 45 and second side outer surface 18 extends from the radialperimeter of first disc panel 32 to hub opening 45. First side innersurface 36 and second side inner surface 18 extend between hub portion12 and tire engaging portion 14. According to one embodiment, first sideinner surface 36 and second side inner surface 38 may have a planer,convex, concave or other shape.

Hub portion 12 includes a hub center 40, a hub index 42 and a disc panelhub flange 44. Hub portion 12 forms a hub opening 45 through wheel 10.Hub opening is shaped to receive a hub. In one embodiment, the portionof hub opening 45 formed by hub center 40 is shaped, proximate to innersurface 38, to receive hub index 42 and act as a hub index receivingarea. During assembly, hub index 42 can slip inside of hub center 40 tohelp ensure that disc panels 32, 34 are aligned and concentric to thewheel center. In addition or in the alternative, disc panel 32 and discpanel 34 may include other alignment features to facilitate alignment ofthe disc panels.

A set of ribs 46 extend between first side inner surface 36 and secondside inner surface 38. Ribs 46 may be molded in panel 32 or panel 34 ormolded separately and bonded to panel 32 and panel 34. A first side ofeach rib 46 may follow the contour of first side inner surface 36 and asecond side of each rib may follow the contour of second side innersurface 38. The ribs 46 are configured to provide structural support towheel 10 both laterally (axially) and in compression (radially).

The ribs 46 may have a variety of shapes and sizes. In the embodiment ofFIG. 3, the ribs each extend primarily radially from an inner radiusthat is spaced from hub center 40 to the radially inner side of tireengaging portion 14. In other embodiments, the radially inner ends ofribs 46 may terminate at hub center 40. Moreover, the radially outerends of ribs 46 may be spaced from the radially inner side of tireengaging portion 14.

According to one embodiment, first disc panel 32 is molded as a singlepanel that includes a circumferential wall that provides tire bed 24,circumferential outer lip 20, circumferential outer lip 22, side panel33, hub center 40 extending axially inward from side panel 33, hubflange 44 extending radially outward from hub center 40 at the end ofhub center 40 that is distal from side panel 33, and molded-in ribs 46.Second disc panel 34 is molded as a single panel that includes sidepanel 35 and hub index 42 that projects axially inward from side panel35.

Disc panels 32, 34 are coupled together after molding, such as by gluingor bonding with another agent. To this end, disc panels 32, 34 may beformed with bonding surfaces so that they can be bonded together. Forexample, a circumferential flat bonding surface 50 is to which discpanel 34 can be bonded is disposed on the inner side of disc panel 32proximate to the radially outer edge of disc panel 32. As anotherexample, surface 52 of hub flange 44 that faces second side innersurface 38 can provide a large bonding surface to which the oppositedisc panel 34 can be bonded. Further, ribs 46 may comprise surfaces 54that face second inner surface 38 and can be used as bonding surfaces towhich the second inner surface 38 can be bonded. If panel 32 includesmolded-in ribs, such ribs may have a bonding surface to which innersurface 36 can be bonded. As another example, the radially outer surfaceof hub index 42 may be bonded to a radially inner surface 41 of hubcenter 40. In addition or in the alternative, disc panel 32 and discpanel 34 may be coupled together using other mechanisms, such as withfasteners.

The foregoing example in which tire bed 24, circumferential outer lip20, circumferential outer lip 22, side panel 33, hub center 40 extendingaxially inward from side panel 33, hub flange 44 extending radiallyoutward from hub center 40 at the end of hub center 40 that is distalfrom side panel 33, and molded-in ribs 46 are molded as a panel isprovided by way of example and not limitation. Various parts of wheelcan be formed separately and joined together. For example, in someembodiments, ribs 46 may be molded separately from disc panels 32 and34. In such an embodiment, they can be bonded or otherwise coupled todisc panel 32 or disc panel 34 before disc panels 32, 34 are bondedtogether.

FIG. 4 depicts another embodiment of a disc panel 60. Disc panel 60 canbe coupled to a second disc panel, such as second disc panel 34, to forma wheel. In the embodiment illustrated, disc panel 60 includes a sidepanel 66 having an outer surface and inner surface 67. The outer surfacemay be similar to outer surface 16 discussed above and extend from anouter perimeter of disc panel 60 to the center opening (e.g., hubopening 63). The inner surface 67 extends between a hub portion and tireengaging portion 64. The outer surface and inner surface 67 of panel 66can have a variety of shapes, such as planer, concave, convex or othershapes.

Disc panel 60 further comprises a hub center 62 and disc panel hubflange 64. A hub opening 63 through hub center 62 is shaped to receive ahub. The portion of hub center 62 distal from side panel 66 may beshaped to receive a hub index (e.g., hub index 42) and act as a hubindex receiving area. During assembly, the hub index can slip inside ofhub center 62 to help ensure that the disc panels being assembled into awheel are concentric to the wheel center. In addition or in thealternative, disc panel 60 may include other alignment features tofacilitate alignment of the disc panels.

An inner set of radially extending ribs 68 and an outer set of radiallyextending ribs 70 extend axially from inner surface 67. A ring-shapedrib 72 that is concentric about the center of panel 66 also extendsaxially from inner surface 67. Ribs 68, 70, 72 extend a sufficientdistance so that they may be bonded to a facing panel. A first side ofeach rib 68, 70, 72 may follow the contour of inner surface 67 and asecond side of each rib may be shaped to follow the contour of the innersurface of an opposite panel (e.g., side panel 35 of FIG. 3) where theribs are to bond to the opposite panel. The ribs 68, 70, 72 areconfigured to provide structural support to a wheel both laterally(axially) and in compression (radially).

The ribs 68, 70, 72 may have a variety of shapes and sizes. In theembodiment of FIG. 4, the ribs 68 each extend primarily radially from aninner radius that is spaced from hub center 40 to an outer radius thatis less than the radius of rib 72. In other embodiments, the radiallyinner ends of ribs 68 may terminate at hub center 40 or the radiallyouter ends of ribs 68 may terminate at rib 72. Further, the ribs 70 eachextend primarily radially from an inner radius that is spaced from rib72 to an outer radius that is spaced from the inner side of tireengaging portion 64. In other embodiments, the radially inner ends ofribs 70 may terminate at rib 72 or the radially outer ends of ribs 70may terminate at the radially inner side of tire engaging portion 64.

According to one embodiment, disc panel 60 is molded as a single panelthat includes a circumferential wall that provides a tire bed or otherwheel outer perimeter surface, a first circumferential outer lip 82, asecond circumferential outer lip 84, side panel 66, hub center 62extending axially inward, hub flange 64, and molded-in ribs 60, 70, 72.

Disc panel 60 and a second disc panel (e.g., disc panel 34 of FIG. 3)can be bonded together after molding, such as by gluing or bonding withanother agent. To this end, disc panels 60 and the second disc panel maybe formed with bonding surfaces so that they can be bonded together. Forexample, the inner side portion of disc panel 60 proximate to theradially outer edge can provide a circumferential bonding surface 74 towhich the opposite disc panel can be bonded. As another example, thesurface of hub flange 64 that faces the opposite panel can provide alarge bonding surface to which the opposite panel can be bonded.Further, ribs 68, 70, 72 may comprise surfaces 76, 78, 80, respectively,that face second inner surface of the opposite panel and can be used asbonding surfaces to which the inner surface of the opposite panel can bebonded. Ribs may also be molded in the opposite panel. Such ribs mayhave a bonding surface to which inner surface 67 can be bonded. Asanother example, the radially outer surface of a hub index (e.g., hubindex 42) may be bonded to a radially inner surface of hub center 62. Inaddition or in the alternative, disc panel 60 and an opposite disc panelmay be coupled together using other mechanisms, such as with fasteners.

In some embodiments, various portions of panel 60 may be formedseparately and then assembled. By way of example, but not limitation,ribs 68, 70, 72 may be molded separately from disc panel 60 and thesecond disc panel and then bonded to disc panel 60 or the second discpanel before disc panel 60 and the second disc panel are bondedtogether.

FIG. 5 depicts another embodiment of an inner side of a disc panel 100.Disc panel 100 can be coupled to a second disc panel, such as seconddisc panel 34 or other disc panel, to form a wheel. Disc panel 100includes a disc side panel 102 having a side outer surface and innersurface 103. The side outer surface may be similar to outer surface 16discussed above and extend from an outer perimeter to a central opening(e.g., hub opening 113). Inner surface 103 extends between a hub portionand tire engaging portion 104. The side outer surface and inner surface103 of disc panel 100 can have a variety of shapes, such as planer,concave, convex or other shape.

Disc panel 100 further comprises a hub center 112 and disc hub flange114. A hub opening 113 through hub center 112 can be shaped to receive ahub. The portion of hub center 112 distal from side panel 102 may beshaped to receive a hub index (e.g., hub index 42) and act as a hubindex receiving area. During assembly, the hub index can slip inside ofhub center 112 to help ensure that the disc panels being assembled intoa wheel are concentric to the wheel center. In addition or in thealternative, disc panel 100 and the opposite disc panel may includeother alignment features to facilitate alignment of the disc panels.

A set of ribs 110 extend axially inward from inner surface 103 asufficient distance so that ribs 110 can be bonded to an inner surfaceof a facing panel (e.g., panel 35 of FIG. 3). A first side of each rib110 may follow the contour of inner surface 103 and a second side ofeach rib 110 may be shaped to follow the contour of the inner surface ofan opposite panel (e.g., the inner surface of panel 35 of FIG. 3) wherethe ribs are to bond to the opposite panel. The ribs 110 are configuredto provide structural support to a wheel both laterally (axially) and incompression (radially).

In the embodiment of FIG. 5, the ribs 110 each extend primarily radiallyfrom an inner radius that is spaced from hub center 112 to an outerradius that is spaced from the radially inner side of tire engagingportion 104. In other embodiments, the radially inner ends of ribs 110may terminate at hub center 112 or, as illustrated in FIG. 3, theradially outer ends of ribs 110 may terminate at the radially inner sideof the tire engaging portion 104.

According to one embodiment, disc panel 100 is molded as a single discpanel that includes a tire bed or other wheel outer perimeter surface, afirst circumferential outer lip 120, a second circumferential outer lip122, side panel 102, hub center 112, hub flange 114, and molded-in ribs110.

Disc panel 100 and a second disc panel (e.g., disc panel 34 of FIG. 3)can be bonded together after molding, such as by gluing or bonding withanother agent. To this end, disc panel 100 and the second disc panel maybe formed with bonding surfaces so that they can be bonded together. Forexample, the inner side portion of disc panel 100 proximate to theradially outer edge can provide a circumferential bonding surface 124 towhich the opposite disc panel can be bonded. As another example, thesurface of hub flange 114 that faces the opposite panel can provide alarge bonding surface to which the opposite panel can be bonded.Further, ribs 110 may comprise surfaces 111 that face an inner surfaceof the opposite panel and can be used as bonding surfaces to which theother panel can be bonded. If ribs are molded in the opposite panel,such ribs may have a bonding surface to which inner surface 103 can bebonded. As another example, the radially outer surface of a hub index(e.g., hub index 42) may be bonded to a radially inner surface of hubcenter 112. In addition or in the alternative, disc panel 100 and asecond disc panel may be coupled together using other mechanisms, suchas fasteners.

In some embodiments, various portions of disc panel 100 may be formedseparately and then assembled together. By way of example, but notlimitation, ribs 110 may be molded separately from disc panel 100 or thesecond disc panel and then bonded to disc panel 100 or the second discpanel before the disc panels are bonded together.

FIG. 6 depicts another embodiment of an inner side of a disc panel 150.Disc panel 150 is another example of a first disc panel that can bejoined to second disc panel, such as second disc panel 34 or other discpanel, to form a wheel. Disc panel 150 includes a disc side panel 152having a side outer surface and inner surface 153. The side outersurface may be similar to outer surface 16 discussed above and mayextend from an outer perimeter of disc panel 150 to a central opening(e.g., hub opening 163). Inner surface 153 may extend between a hubportion and tire engaging portion 154. The outer surface and innersurface 153 of panel 152 can have a variety of shapes, such as planer,concave, convex or other shape.

Disc panel 150 may further comprise a hub center 162 and disc hub flange164. A hub opening 163 through hub center 162 is shaped to receive ahub. The portion of hub center 162 distal from side panel 152 may beshaped to receive a hub index (e.g., hub index 42) and act as a hubindex receiving area. During assembly, the hub index can slip inside ofhub center 162 to help ensure that the disc panels being assembled intoa wheel are concentric to the wheel center. In addition or in thealternative, disc panel 150 and the opposite disc panel may includeother alignment features to facilitate alignment of the disc panels.

A set of right angled ribs 170, 171 extend axially inward from innersurface 153 a sufficient distance so that ribs 170, 171 can be bonded toan inner surface of a facing panel (e.g., panel 34). In the embodimentof FIG. 6, the ribs 170 and 171 are placed to form a set of “X”patterns. A first side of each rib 170, 171 may follow the contour ofinner surface 153 and a second side of each rib 170, 171 may be shapedto follow the contour of the inner surface of an opposite panel (e.g.,panel 35 of FIG. 3) where the ribs are to bond to the opposite panel.The ribs 170, 171 are configured to provide structural support to awheel both laterally (axially) and in compression (radially).

According to one embodiment, disc panel 150 is molded as a single panelthat includes a tire bed or other wheel outer perimeter surface, a firstcircumferential outer lip 172, a second circumferential outer lip 174,side panel 152, hub center 162, hub flange 164 extending radiallyoutward from hub center 162, and molded-in ribs 170, 171.

Disc panel 150 and a second disc panel (e.g., disc panel 34 of FIG. 3)can be bonded together after molding, such as by gluing or bonding withanother agent. To this end, disc panel 150 and the second disc panel maybe formed with bonding surfaces so that they can be bonded together. Forexample, the inner side portion of disc panel 150 proximate to theradially outer edge can provide a circumferential bonding surface 176 towhich the opposite disc panel can be bonded. As another example, thesurface of hub flange 164 that faces the opposite panel can provide alarge bonding surface to which the opposite panel can be bonded.Further, ribs 170, 171 may comprise surfaces 180, 181 that face an innersurface of the opposite panel and can be used as bonding surfaces towhich the other panel can be bonded. If ribs are molded in the oppositepanel, such ribs may have a bonding surface to which inner surface 153can be bonded. As another example, the radially outer surface of a hubindex (e.g., hub index 42) may be bonded to a radially inner surface ofhub center 162. In addition or in the alternative, panel 150 and anopposite disc panel may be coupled together using other mechanisms, suchas fasteners.

In some embodiments, various portions of disc panel 150 may be formedseparately and then then assembled together. By way of example, but notlimitation, ribs 110 may be molded separately from disc panel 100 or thesecond disc panel and then bonded to disc panel 100 or the second discpanel before the disc panels are bonded together.

FIG. 7 and FIG. 8 illustrate, respectively, another embodiment of afirst disc panel 200 and a second disc panel 250 that can be assembledinto a disc wheel. Disc panel 200 is similar to disc panel 100 but hasfewer ribs 210. Disc panel 250 is similar to disc panel 34, but includesribs 260. Ribs 210 and ribs 250 are spaced so that, when first discpanel 200 and second disc panel 250 are assembled, ribs 210 and ribs 260are positioned between each other.

Disc panel 250 includes a disc side panel 252 having an outer surfaceand inner surface 253. The side outer surface may be similar to outersurface 18 discussed above. The side outer surface may extend radiallyfrom a radially outer perimeter of disc panel 250 to a central opening(e.g., a hub opening). The side outer surface and inner surface 253 ofpanel 252 can have a variety of shapes, such as planer, concave, convexor other shape. A hub index 254 projects axially inward from side panel252 and forms a portion of a hub opening that is shaped to receive ahub. During assembly, the hub index 254 can slip inside of a hub center(e.g., hub center 212 of FIG. 7) to help ensure that the disc panelsbeing assembled into a wheel are concentric to the wheel center. Inaddition or in the alternative, disc panels 200 and 250 may includeother alignment features to facilitate alignment of the disc panels.

A set of ribs 260 extend axially inward from inner surface 253 asufficient distance so that ribs 260 can be bonded to an inner surfaceof a facing panel (e.g., the inner surface of side panel 202 of discpanel 200). A first side of each rib 260 may follow the contour of innersurface 253 and a second side of each rib 260 may be shaped to followthe contour of the inner surface of an opposite panel 202 where the ribsare to bond to the opposite panel. The ribs 260 are configured toprovide structural support to a wheel both laterally (axially) and incompression (radially).

In the embodiment of FIG. 8, the ribs 260 each extend primarily radiallyfrom an inner radius that is spaced from hub index 254 to an outerradius that is spaced from the radially outer edge of disc panel 250. Inother embodiments, the radially inner ends of ribs 260 may terminate athub index 254 or the radially outer ends of ribs 260 may terminate atanother position.

According to one embodiment, disc panel 250 is molded as a single panelthat includes side panel 252, hub index 254 and molded-in ribs 260. Discpanel 250 and disc panel 200 can be bonded together after molding, suchas by gluing or bonding with another agent. To this end, disc panel 200and disc panel 250 may be formed with bonding surfaces so that they canbe bonded together. For example, the inner side portion of disc panel200 proximate to the radially outer edge can provide a circumferentialbonding surface 224 to which circumferential bonding surface 264 on theinner side of disc panel 250 can be bonded. As another example, thesurface of hub flange 214 that faces panel 252 provides a large bondingsurface to which a bonding surface 266 of panel 260 can be bonded.Further, ribs 210 may comprise surfaces 211 to which the inner surface253 of panel 252 can be bonded. Similarly ribs 260 may include bondingsurfaces 262 to which the inner surface of panel 202 can be bonded. Asanother example, the radially outer surface of a hub index 254 may bebonded to a radially inner surface of hub center 212. In addition or inthe alternative, disc panels 200 and 250 may be coupled together usingother mechanisms, such as with fasteners.

In some embodiments various portions of disc panels 200 and 250 may beformed separately and then assembled together. By way of example, butnot limitation, ribs 210, 260 may be molded separately from disc panels200, 250 and then bonded to disc panel 200 or disc panel 250 prior toassembly of the disc panels into a wheel.

Disc panels and wheels with internal ribs, such as disc panels andwheels described above, can be formed of composite materials, such asfiber reinforced polymers. By way of example, but not limitation, discpanels and wheels with internal ribs may be formed from fiber glasscomposite material or carbon fiber composite material. Internalcross-ribs, that is ribs that extend laterally from side panel to sidepanel, allow the panels to be lighter while retaining stiffness andstrength. Accordingly, an all composite material disc wheel, such as anall carbon fiber disc wheel, with relatively thin walls can be formedwithout requiring a structural core material, such as a honeycombmaterial. In other embodiments, a disc wheel with internal ribs or otherinternal braces may include a structural core material.

According to one embodiment, ribs or other braces can be molded into apart by use of a “trapped rubber” process. For example, the ribs can bemolded into a disc panel using shaped pieces of silicone or otherflexible, expanding rubber or other material to position and supportbraces during the molding process. The material for the shaped piecescan be selected to withstand the molding temperatures and pressures,while remaining flexible enough so that the shaped pieces can be removedafter molding. One embodiment of a “trapped rubber” molding process isdiscussed below.

FIG. 9 is a sectional view of one embodiment of a mold 300 for molding adisc panel. FIG. 10 is a partially exploded view of mold 300. FIG. 11illustrates one embodiment of a portion of mold 300. Mold 300 comprisesa plurality of mold pieces that form a mold cavity 320 shaped to mold adisc panel. Mold 300 may be formed from any number of pieces. The piecesmay be made of a variety of materials, such as aluminum or othermaterials, capable of withstanding the temperatures and pressures usedin the molding processes.

In the embodiment illustrated, mold 300 comprises a mold portion 302, amold portion 304 and a center pin 306. Mold portion 302, mold portion304 or center pin may be formed of one or more parts. In the embodimentillustrated, for example, mold portion 302 includes mold piece 305 andmold pieces 303. Center pin 306 comprises first portion 310 and secondportion 312. Center pin first portion 310 can be coupled to mold piece305 with fastener 314 and center pin second portion 312 can be coupledto mold piece 304 with fastener 316.

Mold portion 302 and center pin 306 provide molding surface to shape ahub portion, side panel and tire engaging portion of a disc panel. Moldportion 304 provides a molding surface to shape the bonding surfaces ofthe disc panel to match the inner side of the opposite disc panel. Moldportion 302 and mold portion 304 can be pressed together under heat tocure a composite material into a disc panel having molded-in ribs.

More particularly, the inner surface 322 of mold piece 305 provides amolding surface to create the outer shape of a side panel. Surface 322may be concave, convex, planer or have another shape to achieve adesired side panel outer surface shape. Inside surface 324 at theradially outer periphery of mold cavity 320 provides a molding surfaceto shape a tire bed (e.g., tire bed 24) or other wheel circumferentialperimeter wall. The radially outer surface 328 of pin 306 provides amolding surface that defines the shape of the hub opening through a hubcenter. The inside surface 326 of mold portion 304 may be convex,concave, planer or have another shape. According to one embodiment,insider surface 326 is shaped like the inside surface of an oppositepanel. For example, if mold 300 is shaped to a mold disc panel that willbe bonded to a disc panel 34 (FIG. 3), then inside surface 326 may beshaped like inside surface 38 of panel 34.

As illustrated in FIG. 11, mold portion 302 and center pin 306 can beassembled to provide a mold area with molding surfaces 322, 324, 328.For example, center pin portion 310 can be coupled to mold piece 305with fastener 314 and center pin portion 312 placed on center pinportion 310. Carbon fiber composite material can be placed on themolding surfaces. For example, as illustrated in FIG. 12, compositepanel material 350, such as carbon fiber composite material or othercomposite material, extends from edge 354 to edge 364 can be positionedover molding surfaces 322, 324, 328. Carbon fiber panel material 350includes material to form side panel 360, tire bed 362, hub centerportion 364, hub flange 366, and an extension 358. Extension 358 canprovide a circumferential bonding surface when panel material 350 hasfully cured into a disc panel.

The panel material 350 may comprise, for example, one or more layers ofpre-impregnated composite materials (e.g., one or more layers ofpre-preg carbon fiber composite material). According to one embodiment,a center cut sheet of composite material, such as carbon fiber compositematerial, is positioned on surface 322 to form a side panel 360 thatextends from inner radius 372 to outer radius 374. Additional layers ofcomposite material can be positioned over the molding surfaces to extendpanel material 350 from radius 374 to edge 356 and from radius 372 toedge 354.

At this point, the panel material 350 could be fully cured into a discpanel without molded-in ribs. For example, panel material can be curedinto a disc panel similar to disc panels 32, 60, 100, 150 or 200, butwithout the respective ribs. Separately molded ribs can then be bondedto the inner surface of the disc panel to form a disc panel 32, 60, 100,150, 200 or other disc panel.

In another embodiment, internal ribs are molded in. For example, ribsformed of a composite material can be arranged on the inner surface ofside panel 360. With the ribs in place, panel material 350 and the ribscan then be baked under pressure and temperature to mold a disc panelwith internal ribs.

In one embodiment, the ribs are wrapped on shaped rib support piecesformed from silicone or other similar flexible, expanding material thatcan withstand the temperatures and pressures of the molding process. Thematerial used for the rib support pieces may also be selected so thatthe ribs do not bond to the rib support pieces during curing. The shapedrib support pieces with the ribs wrapped thereon can be placed on theinside surface of side panel 350 prior to baking. The rib support piecessupport the ribs and maintain the ribs in desired positions as the panelis backed. Furthermore, the rib support pieces may expand during thebacking process to assert additional pressure on the ribs and panelmaterial. The ribs bond to the inside surface of panel 360 during bakingas the ribs cure and thus become molded into the panel. The rib supportpieces can then be removed after the disc panel has cured.

The shape, placement and wrapping of the rib support pieces can beselected to control the resulting internal rib pattern. The rib supportpieces can be shaped, positioned and wrapped to form, for example, ribs46, 68, 70, 72, 110, 170, 171, 210 or other ribs or braces that extendaxially inward from the inner surface of a side panel.

FIG. 13 illustrates one embodiment of shaped rib support pieces 380. Inthe illustrated embodiment, each rib support piece 380 is a “pie piece”shape and has a radially inner end 382 generally shaped to conform tomolding surface 328 of center pin 306, a radially outer end having asurface generally shaped to conform to molding surface 324, a surface386 that will face molding surface 322 during molding, a surface 388that will faces mold portion 304 during molding and surfaces 390 thatextend between inner end 382, outer end 384 and surfaces 324, 326. Thesurfaces of a rib support piece 380, such as changes in height or otherfeatures. Shaped rib support pieces 380 can be made of silicone or otherflexible, expanding rubber or other material selected to withstand thetemperatures and pressures of the molding process while remainingflexible enough so that the shaped pieces can be removed from the moldeddisc panel without breaking the molded part.

A rib formed from a composite material, such as a pre-preg carbon fiberply, can be wrapped on a rib support piece 380 over a surface 490. Therib can be folded over to at least partially overlap surface 386 andsurface 388. The rib may also be wrapped to at least partially overlapradially inner end 382 and radially outer end 384 of the adjacent ribsupport piece 380. Thus, ribs may include a portion of ply that getsfolded over such that it will overlap multiple surfaces of the adjacentshaped rib support piece 380. FIG. 14 illustrates one embodiment of across-section of a rib support piece 380 with a rib 400 wrapped over asurface 390 (FIG. 13). Rib 400 comprises a portion 402 folded oversurface 386 and a portion 404 folded over surface 388. During a moldingoperation, portion 402 is pressed against an inner surface of a sidepanel (for example, the inner surface of side panel 360) such that rib400 and side panel mold together as the composite material cures. Theheight “h” of the rib support piece is sufficient so that portion 404can be shaped by molding surface 326 (FIG. 9) during the moldingprocess.

In FIG. 14, rib 400 is wrapped on a single rib support piece 380 to forma “C” shaped rib. However, one or more layers of composite material canalso be folded over an adjacent rib support piece to create an “I”-beamshaped rib.

FIG. 15 illustrates a view of one embodiment of mold portion 302 withseveral rib support pieces 380 and ribs arranged on the panel material350 that extends from edge 345 to edge 356. In this example, each rib400 is wrapped on an adjacent rib support piece 380. Rib portions 404 a,404 b and 404 c may be folded over to overlap the surface 388 of theadjacent rib support piece 380 (rib portion 404 a is shown fully foldedover, but rib portions 404 b and 404 c are depicted, for the purposes ofillustration, as not yet fully folded over). A rib 400 may also befolded over surface 386 of the adjacent rib support piece 380 (e.g.,each rib 400 may include a portion 402 as shown in FIG. 14 that foldsover the adjacent rib support piece). In some embodiments, a rib 400 mayalso be folded over the radially inner end 382 (FIG. 13) or radiallyouter end 384 (FIG. 13) of the rib support piece 380.

During curing, the portion of a rib 400 that is folded over rib supportpiece surface 386 (e.g., portion 402 of FIG. 14) will bond to the innersurface of side panel 360 while the portion of the rib that is foldedover rib support piece surface 388 (e.g., rib portions 404 a, 404 b, 404c) will be shaped to provide bonding surfaces that match the contour ofthe inside surface of an opposite panel. Similarly, if a portion of arib 400 is folded over inner end 382, that portion will bond to the hubcenter and, if a portion of the rib 400, is folded over the radiallyouter end 384, that portion will bond to the radially inner surface ofthe tire engaging portion.

FIG. 16 is a perspective view of one embodiment of mold portion 302 withrib support pieces 380 and ribs 400 arranged on panel material 350 (inFIG. 15, only hub flange 366 and extension 358 of panel material 350 arevisible). With the rib support pieces 380 and ribs 400 in place as shownin FIG. 15, the mold portion 304 can be lowered on to complete mold 300.Fastener 316 may be used to further secure center pin 306 (see FIG. 10).Mold 300 is placed in a press and heat and pressure applied to curepanel material 350 and ribs 400. In some embodiments, the baking processcan occur at over 100 psi. In any case, the cooking process can occur asappropriate for the resin system being used. As one of ordinary skill inthe art will appreciate, resin systems may be flexible in their curecycles. For example, using a particular resin system, a manufacturer cancure a part at 230 F for 1 hour or at 280 F in 3 minutes using the sameresin. The process may be relatively slow (temperature reduced, timeincreased) to allow the silicone to expand but to prevent the silicone(or other material) from expanding and breaking the molds. Thetemperature/time selection can depend at least in part on the robustnessof the molds. In some embodiments, the mold may be robust enough thatthe expansion of higher temperatures could be contained without breakingthe mold such that higher temperatures/shorter times can be used.

Shaped pieces of expandable material, such as rib support pieces 380,facilitate bonding and shaping of composite material by expanding to putaxial, radial and circumferential (perpendicular to axial and radial)pressure on the composite material. For example, rib support pieces 380can expand axially to press flange 366 and extension 358 against moldingsurface 326 and press side panel 360 against molding surface 322.Moreover, axial expansion can cause a shaped piece 380 to press a ribportion 402 against panel material 350 and press a rib portion 404against molding surface 326. Shaped pieces can also expand radially topress tire bed 362 against molding surface 324 and center portion 364against molding surface 328. If a rib 400 is folded over radially innerend 382, radial expansion of support piece 380 can cause the rib supportpiece 380 to press that portion of the rib 400 against the outer surfaceof hub center portion 364. Similarly, if a rib 400 is folded overradially outer end 384, radial expansion of a support piece 380 cancause the support piece 380 to press that portion of the rib against theradially inner surface of tire bed 362. A rib support piece 380 canexpand circumferentially to put pressure on the portions of ribs 400sandwiched between support pieces 380.

When the disc panel has finished its heat cycle, it can be removed fromthe heat/pressure and allowed to cool. Because the rib support piecesare flexible, they can be wriggled out from between the ribs withoutbreaking the ribs or other portions of the molded part. The molded discpanel with molded-in internal ribs can be removed from the mold.

Using the arrangement of FIG. 15, the molded disc panel removed from themold can be similar to disc panel 32, but with a different configurationof ribs. For example, in contrast to ribs 46 depicted in FIG. 3, theradially inner ends of ribs 400 are bonded to hub center portion 364 andthe radially outer ends of ribs 400 are bonded to the radially innerside of the tire engaging portion.

A complimentary disc panel, such as disc panel 32 can also be molded,with or without ribs, using an appropriate mold shape. The separatelymolded disc panels can then be joined to form an all composite materialdisc wheel, such as an all carbon fiber disc wheel.

FIG. 17 illustrates another example of shaped pieces that can be used toachieve a desired rib configuration. The embodiment of FIG. 17 includesrib support piece 410 and shaped spacers 412. Rib support piece 410 andspacers 412 can be made of silicone or other flexible, expanding rubberor other material selected to withstand the temperatures and pressuresof the molding process while remaining flexible so that they can beremoved from the molded disc panel. Although only one rib support piece410 is illustrated, multiple rib support pieces 410 may be used in amolding process.

A rib that has not been fully cured can be wrapped over surface 414 tofold over surfaces 416 and 418, similar to as illustrated in FIG. 14with respect to shaped piece 380. The rib may also be wrapped over theradially inner end 420 and radially outer end 422 of rib the supportpiece 410. This process may be repeated for multiple ribs. Spacers 412can be placed in the mold about the portion of the panel material thatforms the center hub. Rib support pieces with ribs disposed thereon maybe placed in a mold. Spacers 412 achieve separation of the ribs from thecenter hub portion. Thus, the embodiment of FIG. 16 may be used tocreate, for example, the rib pattern of FIG. 3.

FIG. 18 illustrates another example of shaped pieces that can be used toachieve a desired rib configuration. In the embodiment of FIG. 18,shaped pieces 430 and 432 can be stacked to form a pie piece shaped ribsupport piece. A composite material may be positioned over surfaces 434and 436 and folded over surfaces 338, 440 (e.g., similar to portions402, 404 of FIG. 14). The composite material may also be folded over theradially inner end 442 or radially outer end 444. In this embodiment,composite material can also be disposed between pieces 430 and 432. Inthis manner, a cross-rib with a circumferentially extending portion(e.g., the portion between pieces 430 and 432) can be created.

In other embodiments, shaped pieces of material (e.g., rib supportpieces or spacers) may be formed from a metal or other material thatexpands under the temperatures used in the molding process. A shapedpiece can be formed of multiple sub-pieces assembled together withfasteners or other mechanisms so that the shaped piece can bedisassembled and removed from the disc panel when the disc panel hasfully cured.

Thus, as one of ordinary skill in the art will appreciate from theforegoing, shaped pieces of various materials can be shaped to achieve avariety of rib configurations, including, but not limited to thosedepicted in FIGS. 3-8.

As discussed above, disc panels can be formed with molded-in ribs. Inother embodiments, the ribs can be molded separately from the discpanels and then bonded to the panels after the panels are molded. FIG.19 illustrates several non-limiting examples of ribs 501, 502, 503, 504,505, 506, 507 that can be molded independent of the side panels andglued in after the fact. These examples include “I” beam shaped ribs(e.g., rib 501) and “C” shaped ribs (e.g., ribs 502, 504, 505, 506,507).

Disc wheels formed as discussed herein may be coreless in that they donot have a core formed of structural foam, a honeycomb material or otherstructural material in addition to the ribs between the side panels. Forexample, in some embodiments there is simply air between the internalcomponents. In other embodiments, a core material may be added.

Moreover, while ribs are used as the primary example of internal braces,other braces may be used. For example, a sheet of carbon fiber compositematerial or other composite material can be disposed in a wave (e.g., asine wave) with the crests of the waves contacting the inner surface ofa first side panel. The wave shape can be formed in a mold usingappropriate shaped pieces. The wave structure can be molded in to thefirst panel at the first set of wave crests. After molding, a seconddisc panel can be bonded to the opposite set of wave crests. The wavestructure can thus provide an internal brace for a disc wheel.

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “has,” “having” or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a process,article, or apparatus that comprises a list of elements is notnecessarily limited only those elements but may include other elementsnot expressly listed or inherent to such process, process, article, orapparatus. Further, unless expressly stated to the contrary, “or” refersto an inclusive or and not to an exclusive or. For example, a conditionA or B is satisfied by any one of the following: A is true (or present)and B is false (or not present), A is false (or not present) and B istrue (or present), and both A and B are true (or present).

Additionally, any examples or illustrations given herein are not to beregarded in any way as restrictions on, limits to, or expressdefinitions of, any term or terms with which they are utilized. Instead,these examples or illustrations are to be regarded as being describedwith respect to one particular embodiment and as illustrative only.Those of ordinary skill in the art will appreciate that any term orterms with which these examples or illustrations are utilized willencompass other embodiments which may or may not be given therewith orelsewhere in the specification and all such embodiments are intended tobe included within the scope of that term or terms. Language designatingsuch nonlimiting examples and illustrations includes, but is not limitedto: “for example,” “for instance,” “e.g.,” “in one embodiment.”

Although specific embodiments have been described, these embodiments aremerely illustrative, and not restrictive of the invention. Thedescription herein of illustrated embodiments of the invention is notintended to be exhaustive or to limit the invention to the precise formsdisclosed herein. Rather, the description is intended to describeillustrative embodiments, features and functions in order to provide aperson of ordinary skill in the art context to understand the inventionwithout limiting the invention to any particularly described embodiment,feature or function, including any such embodiment feature or functiondescribed in the Abstract or Summary. While specific embodiments of, andexamples for, the invention are described herein for illustrativepurposes only, various equivalent modifications are possible within thespirit and scope of the invention, as those skilled in the relevant artwill recognize and appreciate. As indicated, these modifications may bemade to the invention in light of the foregoing description ofillustrated embodiments of the invention and are to be included withinthe spirit and scope of the invention. Thus, while the invention hasbeen described herein with reference to particular embodiments thereof,a latitude of modification, various changes and substitutions areintended in the foregoing disclosures, and it will be appreciated thatin some instances some features of embodiments of the invention will beemployed without a corresponding use of other features without departingfrom the scope and spirit of the invention as set forth.

Reference throughout this specification to “one embodiment”, “anembodiment”, or “a specific embodiment” or similar terminology meansthat a particular feature, structure, or characteristic described inconnection with the embodiment is included in at least one embodimentand may not necessarily be present in all embodiments. Thus, respectiveappearances of the phrases “in one embodiment”, “in an embodiment”, or“in a specific embodiment” or similar terminology in various placesthroughout this specification are not necessarily referring to the sameembodiment. Furthermore, the particular features, structures, orcharacteristics of any particular embodiment may be combined in anysuitable manner with one or more other embodiments. It is to beunderstood that other variations and modifications of the embodimentsdescribed and illustrated herein are possible in light of the teachingsherein and are to be considered as part of the spirit and scope of theinvention.

In the description herein, numerous specific details are provided, suchas examples of components and/or methods, to provide a thoroughunderstanding of embodiments of the invention. One skilled in therelevant art will recognize, however, that an embodiment may be able tobe practiced without one or more of the specific details, or with otherapparatus, systems, assemblies, methods, components, materials, parts,and/or the like. In other instances, well-known structures, components,systems, materials, or operations are not specifically shown ordescribed in detail to avoid obscuring aspects of embodiments of theinvention. While the invention may be illustrated by using a particularembodiment, this is not and does not limit the invention to anyparticular embodiment and a person of ordinary skill in the art willrecognize that additional embodiments are readily understandable and area part of this invention. Any dimensions provided are provided by way ofexample and other embodiments may be sized as needed or desired.

It will also be appreciated that one or more of the elements depicted inthe drawings/figures can also be implemented in a more separated orintegrated manner, or even removed or rendered as inoperable in certaincases, as is useful in accordance with a particular application.

Benefits, other advantages, and solutions to problems have beendescribed above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any component(s) thatmay cause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeature or component.

What is claimed is:
 1. A bicycle disc wheel comprising: a first discpanel having a first side outer surface and a first side inner surface,the first side outer surface radially extending from a first disc panelouter perimeter to a center opening; a second disc panel having a secondside outer surface and a second side inner surface, the second sideouter surface radially extending from a second disc panel outerperimeter to the center opening and the second side inner surfaceaxially spaced from and facing the first side inner surface; and aplurality of internal braces coupled to the first side inner surface andthe second side inner surface that provide radial and axial structuralsupport to the first disc panel and second disc panel.
 2. The bicycledisc wheel of claim 1, wherein the plurality of internal bracescomprises a plurality of ribs molded in the first disc panel.
 3. Thebicycle disc wheel of claim 2, wherein the plurality of internal bracescomprises a plurality of ribs molded in the second disc panel.
 4. Thebicycle disc wheel of claim 1, wherein the plurality of internal bracescomprises a radially extending rib coupled to the first side innersurface and the second side inner surface.
 5. The bicycle disc wheel ofclaim 1, wherein the plurality of internal braces comprises a circularrib concentric to the center opening, the circular rib coupled to thefirst side inner surface and the second side inner surface.
 6. Thebicycle disc wheel of claim 3, further comprising: an internal hubcenter; a circumferential perimeter wall.
 7. The bicycle disc wheel ofclaim 6, wherein the plurality of braces comprises a radially extendingrib coupled to the first side inner surface and the second side innersurface, the radially extending rib extending radially from the internalhub center to the circumferential perimeter wall.
 8. The bicycle discwheel of claim 6, wherein the plurality of braces comprises a radiallyextending rib coupled to the first side inner surface and the secondside inner surface, the radially extending rib spaced from the internalhub center.
 9. The bicycle disc wheel of claim 8, wherein the radiallyextending rib is spaced from the circumferential perimeter wall.
 10. Thebicycle disc wheel of claim 1, wherein the second disc panel is bondedto the first disc panel at a plurality of bonding surfaces.
 11. Thebicycle disc wheel of claim 10, wherein the plurality of bondingsurfaces comprises bonding surfaces on the plurality of braces.
 12. Thebicycle disc wheel of claim 1, wherein the bicycle disc wheel is an allcarbon fiber disc wheel.
 13. A method of manufacturing a bicycle discwheel comprising: positioning a panel material on a molding surface of amold; arranging a set of shaped pieces and ribs on an inner surface ofthe panel material, the set of shaped pieces supporting the ribs on thepanel material and formed of an expanding material; baking the mold tocure the panel material and the ribs into a first disc panel withmolded-in ribs; removing the set of shaped pieces from between themolded-in ribs; and bonding a second disc panel to the first disc panelto form a disc wheel with the molded-in ribs providing internal crossribs.
 14. The method of claim 13, wherein bonding the second disc panelto the first disc panel comprises bonding an inner surface of the seconddisc panel to bonding surfaces of the molded-in ribs.
 15. The method ofclaim 14, wherein bonding the second disc panel to the first disc panelcomprises bonding the inner surface of the second disc panel to acircumferential bonding surface on an inner side of the first discpanel.
 16. The method of claim 15, wherein bonding the second disc panelto the first disc panel comprises bonding the inner surface of thesecond disc panel to a hub flange of the first disc panel.
 17. Themethod of claim 13, wherein arranging the set of shaped pieces and ribson the inner surface of the panel material comprises arranging the setof shaped pieces and ribs to form a radially extending rib.
 18. Themethod of claim 17, wherein the radially extending rib extends radiallyfrom an internal hub center to a circumferential perimeter wall.
 19. Themethod of claim 17, wherein the radially extending rib is spaced from aninternal hub center.
 20. The method of claim 17, wherein the radiallyextending rib is spaced from a circumferential perimeter wall.